Armature winding and commutator connecting machine



1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE l2 Sheets-Sheet 1 Original Filed Aug. 2, 1954 INVENTORS A FZFrc/me Feb. 16, 1965 w. A. FLETCHER ETAL 3,

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE l2 Sheets-Sheet 2 Original Filed Aug. 2, 1954 I w d INVENTORS g MAL/0M A. flare/me 75 5/2 flrroe/yer Feb. 16, 1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE Original Filed Aug. 2, 1954 12 Sheets-Sheet 5 i I f/ y Maxi. 75

1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE l2 Sheets-Sheet 4 Original Filed Aug. 2, 1954 Kr 0 E m N QQQ w 0) WWW fifi/ NQQ INVENTORS Mum/v A. Esra/me By /74X 5. 7500 Feb. 16, 1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE l2 Sheets-Sheet 5 Original Filed Aug. 2, 1954 m mm M OMHE mg m Feb. 16, 1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE wmnmc AND COMMUTATOR CONNECTING MACHINE Original Filed Aug. 2, 1954 12 Sheets-Sheet 6 mmvroxs Mae/v A! Eire/me BY Ax E. 7000 firs/e Arraawy 1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE l2 Sheets-Sheet 7 Original Filed Aug. 2, 1954 R N WZ 7//////////A/4 U 7m 1% i v, i J m r m INVENTORS lit/14 714. FZETCf/EE BY AX E- 7600 Feb. 1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE 12 Sheets-Sheet 8 Original Filed Aug. 2, 1954 mmvroas 14/44 z/AM A fZH'c/nse BY 4x 5 7500 Feb. 16, 1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE Original Filed Aug. 2, 1954 12 Sheets-Sheet 9 INVENTORS MAL/4M A fze'rcrme BY Maxi. 7200 7175/2 Hrroxewxf 1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE Original Filed Aug. 2, 1954 12 Sheets-Sheet 10 Maj 1 VENTORS MAM/1A l'fcflffn/va BY MAX f. 7500 1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE 12 Sheets-Sheet 11 Original Filed Aug. 2, 1954 e a H Y w mm ww W4 m mM4 r m M 0 m V M5 1965 w. A. FLETCHER ETAL 3,169,301

ARMATURE WINDING AND COMMUTATOR CONNECTING MACHINE 12 Sheets-Sheet 12 Original Filed Aug. 2, 1954 /INVENTOR5 uumvA/Qn'a/se MGM 5. 7500 THE/E Arroemsy United States Patent Ofiice 3,1623% APEQATURE Wll lBlNG AND QZEQMUTIGR CGNNEQIENG MAQL iNE William A. Fletcher, Dalevilie, and Max E. Todd, Winch fail, nth, assignors to General Motors Corporation, Eetroit, Mich a corporation of Belavvare Griginal application Aug. 2, res-a. Ser. No. 447,256

Patent No. 3,i$2,253, dated Get. 3, rasr. and application dune l6, E96 Ser. No. 126,467 8 tClmms. (Cl. 29-33},

This invention relates to the manufacture of armatures for dynamoelectric machines and is particularly concerned with a method and apparatus for mechanically winding the same.

This application is a division of co-pending application, Ser. No. 447,266, filed on August 2, 1954, and now Patent 3,602,259.

Attempts have been heretofore made to mechanically perform certain of the Winding operations on unwound armature assemblies so as to reduce the cost of manufacture of d'ynamoelectric machines and to provide a more perfect balanced armature. Some of these attempts have included the preforming of coils in one machine, the inserting of these preformed coils in slots of the armature core by another machine and subsequently inserting the ends of the inserted coil wires in proper slots in the commutator by still another machine. Another attempt to mechanically wind armatures included the forming of coils of wire directly on the armature core by a machine and subse uently identifying each of the leads so that they might be subsequently placed in the proper commutator slots by another machine. A still further attempt to mechanically wind armatures includes the utilization of a commutator with hooks formed on the commutator bars. These books are used to hold the ends of completed coils of wire which were wound on the armature core as the armature was revolved past a stationary wire guide. The insulation of the ends of Wire in contact with the hooks is then removed by some suitable operation such as brushing, prior to the soldering of the wires to the books.

It is apparent that none of these attempts has successfully provided a machine which will completely wind and stake the ends of the windings into commutator slots. Further, none of these provide a machine wherein the above is accomplished while the armature was held in longitudinally fixed position so that the ends of the coils could be staked in proper slots in the commutator by the machine during the winding operation so that the solderirrg operation can be performed without further operations.

It is an object, therefore, of the present invention to provide an apparatus for completely and automatically winding an armature assembly and staking the ends of the windings in the proper slots in the slotted commutator.

it is another object of the present inventionto provide an apparatus for simultaneously Winding two coils of insulated coated wire on opposite sides of an armature core and to stake the ends of these coils in the proper slots of a commutator, and by repeating the winding and stai ing operations in the same machine after the machine indexes itself to provide a completely wound armature assembly that is in substantially perfect dynamic balance.

It is a further object or" the present invention to wind an armature with nylon coated wire in the machine that completely winds the armature and stakes the ends of the windings in proper commutator slots so as to eliminate the brushing of wires before the soldering of wire ends to the commutator.

It is another object of the present invention to wind an armature assembly in the machine that maintains the armature in a fixed longitudinal position while other porarsasi Patented Feb. 16, 1%85 tions of the machine rotate the armature during the winding operation so as to present the proper core slots and commutator slots to the winding and staking means that operate in a timed sequential relation with each other.

Another object of the present invention is to provide an automatic machine adapted to hold an armature assembly for receiving windings thereon and to rotate said assembly in timed relation to a movable winding arm which guides the nylon covered Wire under proper tension. when the coils are formed upon said assembly.

'An additional object or the present invention is to provide an indexing mechanism in association with armature assembly, winding arm and staking mechanisms whereby the machine will automatically wind 21 complete. series of armature coils on said assembly and stake the endsof said coils in proper commutator slots without requiring the attention of the operator after the assembly has been positioned in the machine.

Further objects and advantages of the present invention will be apparent from the following description, reference being had to the accompanying drawings wherein a preferred embodiment of the present invention is clearly shown.

In the drawings:

FIGURE 1, in perspective, diagrammatically shows various parts of the machine according to the present invention.

FIGURE 2, in perspective, shows a partially Wound armature as positioned in the machine.

FlGURE 3 shows an unwound armature prior to the positioning thereof in the armature winding machine.

FlGURE 4 shows one form of a wiring diagram of an armature which may be wound in the armature winding machine according to thepresent invention.

FIGURE 4A diagrammatically shows the sequence of winding and staking of-two coils.

. FlGURE 5 is a broken away view partly in section showing a collet for grasping the armature, and the means for rotating the armature during the winding operation.

FIGURE 6 is a broken away view partly in section showing the means for indexing the machine for changmg the position of the armature relative to the wire guides as shown in FIGURE 1.

FIGURE 7 partly in section shows the location of the staking punches in a normal position.

FIGURE 8 is 'a perspective view of the wirevhoiding the Wire pinching means which hold the wire during the staking operation.

FIGURE 9 shows a Wire as looped over a horn in the wire holding means and as pinched in position by the wire pinching means as in FIGURE 8.

FlGURE 10 is a plan view partly in section showing the arrangement of various portions of the machine.

FlGURES 11 and 11A are broken-away views showing the punches as inserting the wires in the bottom of the commutator slots. 7

FIGURES 12 and 12A are views similar to'FIGURE 11 wherein shorter punches stake the wires in the top of Description of apparatus The armature winding machine shown diagrammatically in perspective in FIGURE 1 has the parts thereof arranged to completely wind the various coils of wire in proper slots in an armature core and insert and stake the ends oft he wound coils into proper slots' in the commutator without human assistance other than that required to load and unload the machine. a

I To. accomplish this result, an unwound armature assembly '20, comprising; a slotted armature core 22 and a commutator 24 is placed in groove26 on armature'nest block 28 so that a tailstock 30, partially shown in FIG- URE 3, will axially move the end 31 of the armature shaft into position within a collet 32 and the end of the commutator 24 against the serrated portions'of a member 37 which, when rotated, by means to be hereinafter described, will rotate the armature in an oscillatory move ment so that the various steps of winding, inserting and staking may be performed at the proper time. The collet 32 is coaxially mounted and slidable within member 37 and extends to a shifter mechanism 39 which is suitably connected with a fluid cylinder 111 which when actuated will cause collet 32 to release its grip on the armature 20.

Member 37, see FIGURE 1, is oscillated over a predetermined range of movement by rack'33 and gear 34. A movable pawl 35, pivoted on gear 34, see FIGURES 1 and 6, has a pin 36 which normally is received in one 'of the circumferentially spaced holes 38 in member 37 so as to couple and drive member 37 through gear 34 so that the serrated end of member 37 is rotated. This is clearly seen as indicated inFIGURE wherein the armature 20 is positioned against the serrated end of V the arrow in FIGURE 1. In actual practice, the cams 40 and 42 are double acting cams of a type sirnilarto cams 84 and 86 shown in FIGURE 1. cams are not desiredfthe elements connected with rack 33 can be biased toward the Cams 4%] and 42 by one or more springs. I V

The wishbone shaped wire guide carrier 50, see FIG- URES 1, 3, and 13, is moved in timed sequence with the 1 oscillatory rotationof member 37 by suitable levers and cam 52, so that a pair of wire guides 54, secured to the arms of wishbone 50, are moved longitudinally along the outer surface of armature 20. The cam 52 which is shown diagramm'aticallycan be a double acting type similar to cams 84 and 86 so that the wishbone 50 is reciprocated in a manner designated by the arrow in FIGURE 1. These wire guides 54 are guided by slots 56 in nest block 28 so that the point of delivery of wire 58 from the guide 54 is causedto substantially follow the outer contours of the armature 20. Slots 56 are shaped and located relative to core 22 so the guides 54 will cause the wire 58 to be axially aligned'with the core 22 slots when the wishbone member 50"has caused the guides 54 to be moved to If double acting guides 54 beyond the end of the armature core 22. this point the movement of wishbone 5t temporarily ceases and the rack 32 rotates member 37 and armature 2% so that the slot indicated as 22A is moved to occupy the position formerly occupied by slot 22C so that the wire is looped over the rear end of the armature core 22. At this point the rotation of the armature by member 37 is'halted while wishbone moves the guides 54 forwardly so that the wire is deposited in the slot which was formerly 22C and is now in the position formerly occupied by slot 22A... This depositing of the wire in the slots and the looping thereof about the respective ends of armature core 22' may be accomplished any number of times as desired as shown in FIGURE 4A wherein four looped coils are wound on each side of the armature. At the conclusion of the winding of the coils, the wishbone 5% is caused to move opposite the horns 60 wherein the inserting and staking operation, to be hereinafter described, is accomplished.

From the above it is manifest that after the machine has wound the wire 58 'to form coils which have the desired number of turns in slots'22A and has staked the ends thereof, intothe slots :25, as seen in FIGURE 3, in commutator 24, the machine'must be indexed so'that an empty slot is presented to the wire guides so that another coil of wire may be wound. The indexing is accomplished by means of pin 62 and plunger 64, shown in FIGURES I and 6, which are actuated by a piston in a fluid cylinder 66. The cylinder 66 causes pin 62 and plunger 64 to simultaneously move, Plunger 64 will move pawl 35 and cause pin 36 to be withdrawn from a hole 38 while pin 62 enters one of the holes 68 in a collar on member 37 so that gear 34 is free to rotate on member 37 while the member 37 is held in position by means of pin 62. At this point cam 42, which has one-half the rotational speed of cam 43 causes rack 33 to move gear 34- a predetermined distance about member 37. Cylinder 66 then is actuated to cause plunger 64 and pin 62 to be withdrawn, and pawl 35 permits pin 36 to be reengaged in one of the holes 38. Rack 33 is then moved by cam 42 to its normal positionto complete the I indexing of member 37 and a fresh slot on the armature either end of the armature core 22 so that when rack 33 rotates member 37 to correspondingly rotate the arma- 'ture 20, the wire will be directed from slot 22A to slot 122C, as seen in FIGURE 3, and simultaneously the wire,

as applied in slot 22B, Wil1 b8 directed to the slot 22D. This'result is duplicated on the commutator 24 end of the core 22 during the winding cycle of the machine and the number of turns applied to form the coil will depend upon the specifications of the armature as set forth in wiring diagram in FIGURE 4 of the drawings which in turn will dictate the shape of the various cams of the apparatus as is apparent to those skilled in the art.

Cams 4t), 42 and'52 are suitably shaped relative to their cam followers so that after the armature 20 is positioned 20 will be presented to the wire guides 54 when they are moved by the wishbone Sil.

From the wiring diagram as shown in FIGURE 4, it is apparent that two wire ends are received in each of the slots 25 of commutator 24. To accomplish this objective longer 76 and shorter 72 staking and cutting punches are provided, as shown in FIGURES 1 and 7, which move horizontally to perform the staking operation. This horizontal movement is accomplished through the operation of the fluid cylinders 74 and levers 75. The I longer of the staking punches 79 is normally presented 'for the staking operation; wherein the wire is inserted into the bottom-of a slot 25 in a bar of commutator 24 as shown in FIGURE 11 of the drawings. When, however, the end of a second wire is to be placed on top of the first wire in one of the slots 25,'fluid cylinder 76 through a suitable. rack and pinion causes the rotation of punch holders 77 so that the punch 72 is in the position as shown in FIGURE 12 for accomplishing the stak-.

- ingoperation shown in FIGURE 14. f

in the machine, as previously indicated, the wire 58 which 7 has its end wrapped around horn 60, as will be hereina after described, will be moved by guides 54 and deposited within slot 22A until the wishbone 50 has moved. the

So the staking operation maybe successfully accom plished it is manifest that the end of each coil of wire 'to be inserted and staked mustbe held improper position relative to theslot 25, before the proper staking punch '76 or 72 is brought into'operation.

This is accomplished by a wire pinching member 80 and a wire holding member 82. The disposition of these members is most clearly seen in FIGURE 8 wherein member 82 is rotatably journalled within member 8%. Previously mentioned wire horns 65B are integrally formed on member 82 and extend'within an opening in member '39 so that the wire guides 54 will loop the ends of the V -wire over the horns 60 as the guides 54 are'moved forsneasoi wardly to the furthest point of their travel and guides 54 are caused to dwell for a moment while member is rotated a few degrees so a to bring the other side of the horn 6% into alignment with the wire guide 54% so that as wishbone 5d causes the wire guide 5:3- to retreat from its farthest forward position, the wire will be looped over the born as. The most forward point of travel of wire guides 5 is beyond that required to wind coils on the armature as can be seen from FIGURE 5 where it is clear that the wire guides must travel adjacent the part 89 to loop the wire over the horns Member 3% then rotates a few degrees in a proper direction, for example, clockwise in FIGURES 9, ll and 12. This rotation of member St? relative to horn 6t, causes the wire to be lightly pinched between the lug surfaces 81 on member 8% and the born 68 to hold the wire in place while one of the punches 76 or 72 is horizontally moved toward the commutator 2 1-, to cause a portion of the wire to pass from between the surface 81 and horn on into slot of commutator as seen in FIGURE 14. Further, as the wire is simultaneously pressed into position in the slot 25 by portion 73 of punches 7% or 72 the wire end is severed from the portion looped about the born as by the knife-like portion 73a of the punches which pass in close proximity to a cutting edge portion of member 82 so as to cause a wire to be sheared at this point and thereby accomplish the simultaneous staking and shear ing operation.

The movement of members 8%, shown diagrammatically in FIGURE 2, is accomplished in a timed equence with the other operations or" the machine by means of cams S4 and 85 which are carried by a common shaft 12-25 that is driventlu'ough suitable gears by motor 1 1. Cam is located and shaped to move the member 3% while member 52 is driven through a suitable U racr; and pinion as seen in FIGURES l and 5 of the drawings, to accomplish the looping of the wires over born as and the pinching of wire 58.

It is apparent that after the staking and severing operation has been performed on wire 58 by punches 7G or 72, any appreciable tension on the wire will cause the wire to be withdrawn from its staked position as it is moved during the initiation of the winding operation by adapted to be actuated through a suitable rack and pinion res by a fluid cylinder sea in a pre etermined sequence of operation with the other portions of the apparatus. The wire 5% is passed between rollers 92 and 95; from which point it is delivered to wire guides 54. Before member 82 moves into pinching engagementwith the wire 58, the fluid actuator 1521-3 causes the roller 96 on the right of the drawing to be moved in a clockwise direction as seen in FEGURE 3 about a roller 92 so that a predetermined slack is imparted to the portion of wire 5'8. disposed betweenthe rollers 2 and 2d and the guides rollers on the left side of the apparatus is caused to rotate in a counterclockwise direction relative to roller 92 in FIGURE 3 so as to impart a predetermined slack to the wire on the other side of the apparatus. The slack imparted-to the wire on both sides of the machine is in this connection it is to be noted that du licate has 14 slots, the clutch 4b? is permitted to rotate l4 revolutions for each armature 26 that is to 'be wound, see FIGURE 4. When the armature 20 is positioned in nest blocl; 23, a locator pin 13% in the block 28, see FIGURE 13, is in a raised position and is received in one of the slots in armature core 22 and thereby indexes the armature 2i relative to the winding machine. The movement of the tail stock 3% into the chucking position closes various circuits in the machinery and causes the locator pin 13% to withdraw so that the sequence of winding and staking operations may take place in a timed sequence.

As seen in FIGURE 1, shafts 1M, 193 and 1% each make one revolution for each revolution of clutch 46 or 14 revolutions per armature. Shaft 122 rotates cams 86 and 84 which operate the indexing of horns tit! and pinch ing member 3. This shaft 122 rotates 14 revolutions per each armature. The cams 84 and $6 each have a pair of lands to cause the members Wherewith they are associated to move to the proper position for the pinching and cutting operation. Shaft res, geared to make one revolution per armature, carries cams 1&8, 11d and 112 each of which operate through micro switches to actuate a ll id pressure cylinder. Cam 1&8 is connected with cylinder 75 and serves to position the staking punches id or 72; in the required position for inserting and staking the Wires either into the inside or outside of the slots in commutator 24. Cam 11.0 operates to move the locating pin 139 and to actuate cylinder 111 for chucking and unchucldng armature 2% at the beginning and end of the winding operations. Cam 112 operates to engage the clutch 46 during the winding and staking cycle. Shaft lltl -l carries and rotates camsll l, 116, 118 and 129 which are operatively connected through suitable micro switches to various pressure cylinders, see FIGURE 10. Cam 114 is used to operate staking cylinder 7 Cam 116 operates the cylinder 192, which provides slack to the wire at the proper point of operation of wishbone 50. Cam 113 is used to energize cylinder as and earn is used to control the tension on the wire by an apparatus not shown.

Operation of machine After an armature 24 is properly positioned in the machine wherein the wires 58 are properly threaded with the proper slack, the various control circuits will be energized and clutch do will be engaged and begin to rotate. At this point wire pinching member till, and horn 60 as carried on member 82. will. be energized through cams 8 and 25 respectively to hold the wire so that cylinder 74- may movepunch 'iii and thereby stake the end of the wire into the bottom of slot 2 of the cornmutator, see

FEGURE 4. The rack 33 will then rotate the armature 29 through member 37 so that slot 7 is inproper position relative to guides 54 and simultaneously carn'52 will cause these guides to move rearwardly and deposit the wire in slot 7. When the cam 52 has caused guides 54 to move to the furthest rear position, the cam 52 will cause the guides 54 to dwell in that position for a move- .ient while the rack 33 as actuated by cam 48 causes member '37 to rotate and present slot 1 to guides 54. Cam 5?. will then move guides 54 forwardly along the armature core 22) to a point intermediate the core 22 and commutator 24 where the movement of the guides is again-momentarily halted while rack 33 rotates member '37 so that slot 7 is again presented for winding and thercby complete one turn of a coil that is to be wound in slots land 7. In the particular embodiment shown in FIG 'URE 4, four turns are formed on each coil. This resuit is accomplished by the'contiguration of earns 52 and 4t After the completed coil is formed in slots 1 and 7, am 52 causes the wire guides 54 to move to the most :orward position beyond the point intermediate the core is and commutator 24 where the wire is suitably pinched, inserted, cut staked by punch 7% into the bottom of bar It in commutator 24. The cam 42, which turns 7 revolutions for each armature 20 to be wound then indexes the commutator 24 so that bar 3 is presented for the inserting, cutting and staking operation by punch 70. It is to be appreciated that the various other mechanisms such as member 80, horn 60, and punch 70 heretofore described, all cooperate to produce this indexing of the commutator 24 by cam 42 and the staking operation by punch 70. u v

v After the wire is staked in the bottom of bar 3 by punch 70 the slots 1 and 7 are presented so that a second coil may be Wound on top of the first coil as heretofore described; After the second coil has been Wound in slots 1 and 7 the commutator is indexed so that bar 2 is presented for the staking operation by punch 72 at the conclusion of which the commutator is indexed by the cam 42 so that bar 4 may be staked by punch 70. It is to be here noted that the first three staking operations are accomplished by punch 70 and thereafter cam 108 causes the staking punches 70 and 72 to alternate when the wires are staked in the inner and outer portions of the slots '25 in thecommutator bars. After the second wire end has been staked in bar 4 of the commutator, cylinder 66 is actuated byv cam 118 and'rack 32 by cam 42 so that the member 37 is indexed and slots 8 and 2 i are presented for winding'and bars 3 and 5 are presented for stakingas shown in FIGURE 2 by the method as outlined above.

Further, as clearly seen in the drawing, two coils of wire are simultaneously wound on each side of armature 20. Thus while one of the wire guides 54 is positioning the wire in slot 7, the other is positioning a wire in slot 14 and while the guide 54 places the return portion of the wire in slot 7 in slot 1, the wire in slot 14 will be returned and deposited in slot 8. The terminal ends of these coils ,are bothsimultaneously pinched, inserted,

cut and staked into the proper slots in the commutator bars byduplicate mechanisms that are located on each .side of the machine which are activated in the proper sequence by mechanisms heretofore described.

'From the above, it is manifest that while the machine and will provide a machine and method whereby 'the armature may be wound in a shorter'period of'time.

Further, the method and apparatus outlined will effect a considerable saving of copper, wire over the methods here- "tofore employed as the only portion of the wire that is wasted, as the armature is wound, is that which is looped perature higher than the mobility and vaporization temperatures .of the nylon when brought into contact with the commutator and the staked ends of the wires will have its heat conducted through the severed ends of a wire and ruptured portions of the coating along the sides of the wire. This heat will be conducted by the copper of the wire to the insulation covering of the wire to cause the nylonito first melt and then quickly vaporize to presenta clean metal surface which readily is solderable to the metallic portions'of the commutator. In this connection it is to be noted that the rupture of the side surfaces of the nylon wire during the insertion of the wire into the commutator slot is important to the success of the present in- 'vention as it aids and concentrates in the heat from he solder to the metallic portion of the end of the wire. which has been staked in the slot and hastens the melting'and vaporization of the nylon coating in this immediate area only without being conducted to and melting the coating on the remainder of the winding. If the rupture of the insulation were not accomplished and localized by the punching operation, the subsequent soldering operation would be very difficult to accomplish as. the heat transfer to the nylon would be delayed as the copper of the wire would not be in contact with a sufficient quantity of solder ,to successfully melt the covering at the point to be soldered without injury to the remainder of the nylon covering on the wire. The armatures as formed according to the present invention when Wound with nylon require no other insulation than that afforded by the nylon coating and when used have been found to operate at a lower temperature than the conventional type armatures heretofore used.

Further as the nylon presents a very tough and durable coating for the wire, it reduces shorts that occur inthe conventionally wound armatures when the wires rub upon each other during the operationrof the machine. It has been found that a very low rejection and/or failure of armatures according to the type herein disclosed occurs when the armatures are properly wound. with the proper about the rounded'portion of the horn 60; This saving of I material along with the considerable saving of labor will provide a wound armature at ,a far less cost than with the methods and apparatuses heretofore employed.

As previously set forth, while the apparatus described 7 may be used to align wire that is coated with any suitable insulation of material, the preferred embodiment as used with the method of the present invention includes the use of nylon as a covering for the wire. This material is highly resistant to abrasion and has good insulative qu-ali- I 'ties. The wire used may be of any suitablethickness providing the insulation is of sufficient thickness to prevent shorts between the wiresand so that the wire will fit irito the slots of the armature core. Itis apparent that insulating coatings other than nylon may be employed providing the material will stand the rigoroustreatment as received during the winding operation and will have a low melting point and a narrow'range of temperature. during the application involved. as it is mobile about 480 F. and has a melting point of 487 F. and goes to the vapor state at a temperature of 560 to 570 F. Thus, solder which has a melting point of 450 F. and which is heated to a temamount of tension on the Wire during the winding operation so as to form the individual coils that'are tightly wound within the slots of the armature to minimize the shifting of the wires when the armature is placed in service.

While the embodiment of the present invention as herein disclosed constitutes a preferred form, it is to be under- 'stood that other forms might be adopted. 7

What is claimed is as follows:

l. A machine for winding coils of Wire on an armature assembly which includes a shaft, a slotted core and a commutator and for inserting conductors into. the slots of the commutator comprising, means for supporting said armature assembly along a fixed longitudinal axis, means for rotating said assembly about said axis in opposite directions, wire guiding means movable substantially parallel to said longitudinal axis for depositing wire in at leastone slotof said core when said assembly is maintained in a fixed rotative position, means for. reciprocating said wire guiding means, said meansfor rotating being operable to rotate said armature assembly a predetermined amount when said wire guiding means reaches an end of said armatially spaced slots of said core, a gripping means, means for moving said gripping means, said gripping means being operatedin synchronism with operation of said means for reciprocating said wire guiding means for gripping a portion of said wire when a predetermined number of coils of wire have been applied to said armature core, a staking means for driving said wire out of said gripping means and into a commutator slot and for substantially simultaneously severing said wire,'and'means for driving said staking means.

2. An armature winding and staking machine for winding coil windings on an armature core and staking conductors to a commutator comprising, a means for supporting an armature assembly which includes an armature core and a commutator supported by a shaft, said means maintaining said core fixed with respect to it longitudinal axis, a reciprocable shuttle member movable substantially parallel to the longitudinal axis of said armature assembly for depositing wire in the slots of said armature core as said shuttle is reciprocated, means for reciprocating said shuttle member, drive means for rotating said armature assembly through a predetermined angular rotation in synchronism with said means for reciprocating said shuttle member, a hook member, means for moving said hook member in an arcuate path around the longitudinal axis of the armature assembly, said shuttle member being capable of laying wire against one side of said hook member during one end of its reciprocation, said hook member being angularly movable whereby said shuttie member can deposit wire against an opposite side of said hook member when said shuttle member moves in an opposite direction, a clamping member movable toward said hook member for gripping said wire between said clamping member and said hook member, means for driving said clamping member, a reciprocable staking blade for driving said wire from between said clamping member and said hook member into a commutator slot, said staking blade being capable of severing said wire, and means for driving said staking blade.

3. A machine for winding coils on a slotted armature core and for inserting conductors in commutator slots of an armature assembly which includes a shaft for supporting the armat re core and the commutator comprising, a means for supporting said armature assembly along a fixed longitudinal axis, means for rotating said armature assembly, a reciprocable wire directing means for guiding wire into the longitudinal slots of the armature core when said armature assembly is stationary, means for driving said wire directing means, said wire directing means being movable across the entire length of said armature core, said means for rotating said assembly operating in synchronism with said means for driving said wire directing means and operable to rotate said armature when said wire directing means has applied a length of wire into one of the slots of the armature core to thereby position the wire across one end of the armature core, said wire directing means being movable beyond one end of said armature towards said commutator, a gripping means operative to grip said wire when said wire directing means is moved beyond the end of the armature core and in a predetermined position substantially adjacent the commutator, means for driving said gripping means, said means for driving said gripping means being synchronized with operation of said means for driving said wire directing means, a staking blade for severing said wire and for driving said wire into a commutator slot after it has been gripped by said gripping means, and means for driving said staking blade.

4. A machine for winding coils of wire in the slots of an armature core and for inserting conductors into commutator slots of an armature assembly which includes a shaft that supports said armature core and said commu tater comprising, means for supporting said armature assembly along a fixed longitudinal axis, means for rotating said armature assembly around said longitudinal axis, reciprocable wire guiding means movable along the exterior of said armature assembly for depositing wire in a slot of said armature core, means for driving said wire guiding means, the means for rotating said assembly and said wire guiding means being synchronized in their movement whereby said wire guiding means is reciprocated and said armature assembly is rotated to form coils of wire in slots of said armature core, a horn member, said wire guiding means being capable of moving to a position where wire is directed to a point adjacent said horn member when coils have been wound on said armature core, clamping means movable towards said horn member for gripping said wire between said born member and said clamping means, means for driving said clamping means, a staking blade operable to sever said wire and to drive said wire from between said clamping means and said horn member into a commutator slot, means for driving said staking blade, said wire directing means thereafter being capable of directing wire into other slots of said armature core, and a means adapted to impart a predetermined slack to the wire that has been driven into one of the commutator slots, said means including a pair of members disposed between said wire guide and a source of supply of wire, one of said members being relatively fixed and the other member being movable a predetermined distance relative to said fixed member for imparting a predetermined slack to said wire when said movable member is moved relative to said fixed member.

5. The machine according to claim 4 where the said pair of members are rollers.

6. A machine for winding coils of wire on an armature core and for inserting conductors into commutator slots of an armature assembly which includes a shaft dor supporting the commutator and armature core comprising, a means for supporting said armature assembly along a fixed longitudinal axis, means for rotating said armature assembly, a reciprocable wire directing means operated in synchronism with the means for rotating said armature assembly whereby coil of wire are applied to the slots of said armature core by said wire directing means by rotating said armature when the wire directing means reaches an end of said armature, means for driving said wire directing means, gripping means for gripping an end of said wire when a coil ha been completely wound on said armature core, means for driving said gripping means, a blade member for severing said wire and driving the wire from said gripping means into a commutator slot, means for driving said blade member, means for indexing said armature assembly to present new slots to said wire directing means, and means for imparting a predetermined slack to the wire after it has been inserted into a commutator and prior to the time that the wire directing means moves axially of the armature assembly, said means including a .pair of members disposed between said wire guide and a source of sup ply of wire with the wire passing therebetween, one of said members being fixed and the other being movable a predetermined distance relative to said fixed member for imparting a predetermined slack to said wire when said movable member i moved relative to said fixed member.

7. The machine according to claim 6 where the fixed member and the movable member are a pair of rollers disposed between the wire directing means and the source of supply of Wire, the movable roll-er being movable a predetermined angular distance about the periphery of the fixed roller.

8. A machine for Winding coils of wire on an armature core and for staking the wire into slots of a commutator of an armature assembly which includes a shaft for supporting the armature core and commutator comprising, means for supporting an armature assembly along a fixed longitudinal axis, reciprocable wire directing means disposed on opposite sides of said armature for simultaneously directing wire into oppositely disposed slots of said armature core as said wire directing means reciprocates, means for driving said wire directing means, means for rotating said armature core in timed relationship with operation of said reciprocating wire directing means whereby wire is directed across the end of the armature core when the wire directing means is at the end of the armature core and the armature core is rotated, a pair of oppositely disposed horns, said wire directing mean being operable to move said wire adjacent said horns when said wire directing means is moved beyondthe end of-the armature core, said horns being movable in an areuate path about the longitudinal axis of said armature assembly, means for moving said horns in said arcuate path when said Wire directing mean has moved the wire adjacent the horns, said wire directing ,means moving in an opposite direction to move the wire around said horns, a clamping means movable toward the horns for gripping the Wire between the horns and means.

UNITED STATES PATENTS Hayes June 16, Baldwin May 28, Collins Mar. 23, Allen May 16, Hunsdorf Aug. 7, Fausset et al. Sept. 25, Moore a Feb. 3, Hunsdotnf Sept. 20, Grove Nov. 13, Caldwell Jan. 13,

Alles Aug. 11, 

1. A MACHINE FOR WINDING COILS OF WIRE ON AN ARMATURE ASSEMBLY WHICH INCLUDES A SHAFT, A SLOTTED CORE AND A COMMUTATOR AND FOR INSERTING CONDUCTORS INTO THE SLOTS OF THE COMMUTATOR COMPRISING, MEANS FOR SUPPORTING SAID ARMATURE ASSEMBLY ALONG A FIXED LONGITUDINAL AXIS, MEANS FOR ROTATING SAID ASSEMBLY ABOUT SAID AXIS IN OPPOSITE DIRECTIONS, WIRE GUIDING MEANS MOVABLE SUBSTANTIALLY PARALLEL TO SAID LONGITUDINAL AXIS FOR DEPOSITING WIRE IN AT LEAST ONE SLOT OF SAID CORE WHEN SAID ASSEMBLY IS MAINTAINED IN A FIXED ROTATIVE POSITION, MEANS FOR RECIPROCATING SAID WIRE GUIDING MEANS, SAID MEANS FOR ROTATING BEING OPERABLE TO ROTATE SAID ARMATURE ASSEMBLY A PREDETERMINED AMOUNT WHEN SAID WIRE GUIDING MEANS REACHES AN END OF SAID ARMATURE CORE, SAID MEANS FOR ROTATING SAID ASSEMBLY AND SAID MEANS FOR RECIPROCATING SAID WIRE GUIDING MEANS BEING OPERATED IN SYNCHRONISM WHEREBY SAID WIRE GUIDING MEANS MOVES BACK AND FORTH WHILE SAID ARMATURE ASSEMBLY IS ANGULARLY OSCILLATED TO APPLY COILS OF WIRE TO CIRCUMFERENTIALLY SPACED SLOTS OF SAID CORE, A GRIPPING MEANS, MEANS FOR MOVING SAID GRIPPING MEANS, SAID GRIPPING MEANS BEING OPERATED IN SYNCHRONISM WITH OPERATION OF SAID MEANS FOR RECIPROCATING SAID WIRE GUIDING MEANS FOR GRIPPING A PORTION OF SAID WIRE WHEN A PREDETERMINED NUMBER OF COILS OF WIRE HAVE BEEN APPLIED TO SAID ARMATURE CORE, A STAKING MEANS FOR DRIVING SAID WIRE OUT OF SAID GRIPPING MEANS AND INTO A COMMUTATOR SLOT AND FOR SUBSTANTIALLY SIMULTANEOUSLY SEVERING SAID WIRE, AND MEANS FOR DRIVING SAID STAKING MEANS. 